Table of Contents
Advertisement
Quick Links
Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency
for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free
family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full contact
information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
Declaration of Conformity
If the outboard motor's serial number plate contains the CE mark in the lower left‑hand corner, the following
statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe Inc.
Park Industriel, de Petit‑Rechain, Belgium complies with the requirements of the following directives and
standards, as amended:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
General steering system
Safety of Machinery Directive
Principles of safety integration (1.1.2)
Noise (1.5.8)
Vibration
Electromagnetic Compatibility Directive
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion
engine driven devices ‑ radio disturbance
characteristics
Electrostatic discharge testing
This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe.
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
ABYC P‑17
EN 292‑1; EN 292‑2; EN 1050
ICOMIA 39/94
ICOMIA 38/94
EN 61000‑6‑3
EN 61000‑6‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN
61000‑4‑3
i
94/25/EC
98/37/EC
89/336/EC
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Mercury 200
Summary of Contents for Mercury 200
-
Page 1: Welcome Aboard
Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage. - Page 2 Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine, Fond du Lac, WI USA...
-
Page 3: Table Of Contents
TABLE OF CONTENTS Warranty Information Transfer Of Warranty.............................. 1 Warranty Registration United States And Canada....................1 Warranty Registration Outside The United States And Canada................1 Outboard Limited Warranty United States, Canada and Europe................2 Outboard Limited Warranty (Confederation of Independent States, Middle-East, and Africa........ 3 3 Year Limited Warranty Against Corrosion...................... - Page 4 TABLE OF CONTENTS Features and Controls Remote Control Features............................. 25 Warning System..............................25 Power Trim and Tilt.............................. 27 Operation Pre-Starting Check List............................31 Operating In Freezing Temperatures........................31 Operating In Salt Water Or Polluted Water......................31 Operating at High Elevations..........................31 Setting Trim Angle While Running Engine at Idle Speed..................
- Page 5 Engine Will Not Start............................51 Engine Runs Erratically............................51 Performance Loss..............................52 Battery Will Not Hold Charge..........................52 Owner Service Assistance Local Repair Service............................53 Service Away From Home............................ 53 Parts And Accessories Inquiries........................... 53 Service Assistance............................... 53 Mercury Marine Service Offices........................... 53...
-
Page 7: Warranty Information
You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information. -
Page 8: Outboard Limited Warranty United States, Canada And Europe
Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. -
Page 9: Outboard Limited Warranty
Outboard Limited Warranty (Confederation of Independent States, Middle‑East, and Africa WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. - Page 10 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.
-
Page 11: Year Limited Warranty Against Corrosion
Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. -
Page 12: Warranty Coverage And Exclusions
Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty. - Page 13 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.
-
Page 14: General Information
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. -
Page 15: High-Speed And High-Performance Boat Operation
For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. -
Page 16: Lanyard Stop Switch
GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob01514 Self‑locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. -
Page 17: Protecting People In The Water
GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. -
Page 18: Passenger Safety Message - Pontoon Boats And Deck Boats
GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. Passenger Safety Message ‑ Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. -
Page 19: Impact With Underwater Hazards
GENERAL INFORMATION ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat. -
Page 20: Exhaust Emissions
GENERAL INFORMATION • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat. • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. •... -
Page 21: Selecting Accessories For Your Outboard
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories. -
Page 22: Recording Serial Number
Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier 61 m (200 ft.) in front of you in 5 seconds. - Page 23 Charging System Output 60 Amps 1. Use only Champion QL77CC Spark Plugs or alternate spark plugs approved by Mercury Marine in these models. Consult a Mercury Marine authorized dealer before replacing spark plugs. Use of improper spark plugs may cause engine damage.
-
Page 24: Component Identification
GENERAL INFORMATION Component Identification ob01522 Top cowl Anode plate Bottom cowl Auxiliary tilt switch Water pump indicator hole Transom brackets Driveshaft housing Gearcase Anti‑ventilation plate Cooling water intake holes... -
Page 25: Installation
INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance. - Page 26 INSTALLATION ob00323 If changing conditions cause the RPM to drop below the recommended range, such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a propeller change or cleaning may be required to maintain performance and ensure the outboards durability. Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.
-
Page 27: Transporting
TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing. -
Page 28: Fuel And Oil
The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). -
Page 29: Fuel Requirements For Engine Break-In
IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Mercury or Quicksilver Premium TC‑W3 2‑Cycle oil is recommended for this engine. For added protection and lubrication, Mercury or Quicksilver Premium Plus TC‑W3 2‑Cycle oil is recommended. If Mercury or Quicksilver outboard oil is not available, substitute another brand of 2‑cycle outboard oil that is NMMA Certified TC‑W3. -
Page 30: Filling Fuel Tank
FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill fuel tanks outdoors away from heat, sparks, and open flames. Remove portable fuel tanks from boat to refill them. -
Page 31: Features And Controls
FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. ob00329 Control handle ‑... - Page 32 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following. Warning Horn Function Sound...
-
Page 33: Power Trim And Tilt
Consult your dealer for assistance. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption and engine operating hours. -
Page 34: Power Trim Operation
FEATURES AND CONTROLS ob00663 Trim switch Trim range of travel Tilt range of travel POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. - Page 35 FEATURES AND CONTROLS WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle.
-
Page 36: Shallow Water Operation
FEATURES AND CONTROLS ob00665 AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system. ob00666 Auxiliary tilt switch SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. -
Page 37: Operation
Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes. -
Page 38: Engine Break-In Procedure
OPERATION ob01079 Engine Break‑in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break‑in Procedure. GASOLINE/OIL BREAK-IN MIXTURE Do not use pre‑mixed gas and oil during break‑in. Oil from the oil injection system will supply adequate lubrication during engine break‑in. - Page 39 OPERATION ob00347 Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. ob00348 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboard to neutral "N"...
-
Page 40: Gear Shifting
OPERATION IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for obstruction. No obstruction may indicate a water pump failure or blockage in the cooling system. These condition will cause the engine to overheat. Have the outboard checked by your dealer. Operating the engine while overheated will cause engine damage. -
Page 41: Maintenance
SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure. -
Page 42: Inspection And Maintenance Schedule
MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •... -
Page 43: Top Cowl Removal And Installation
MAINTENANCE ob01518 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. ob01519 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. ob01086 Lift front of cowl to clear front latch and push toward the rear to clear rear hooks. Lift top cowl to remove. -
Page 44: Steering Link Rod Fasteners
MAINTENANCE Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain the fuel system completely. Use an approved container to collect and store fuel. Wipe up any spillage immediately. Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area. -
Page 45: Fuse Replacement
MAINTENANCE ob00676 Special washer head bolt (10‑849838) Nylon insert locknut (11‑826709113) Flat washer (2) Nylon insert locknut (11‑826709113) Description lb. in. lb. ft. Special washer head bolt Nylon insert locknut "d" Nylon insert locknut "c" Tighten until seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and self‑locking nylon insert locknut. -
Page 46: Corrosion Control Anode
MAINTENANCE 3381 Good fuse Accessories ‑ 20 AMP fuse Blown fuse Ignition coil circuit ‑ 20 AMP fuse SmartCraft data bus circuit ‑ 5 AMP fuse Electric fuel pump/ECM driver power/oil pump circuit ‑ 20 AMP fuse Corrosion Control Anode Your outboard has corrosion control anodes at different locations. -
Page 47: Propeller Replacement
MAINTENANCE Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals. - Page 48 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon.
-
Page 49: Spark Plug Inspection And Replacement
MAINTENANCE ob00421 Propeller nut Propeller Propeller nut retainer Replaceable drive sleeve Rear thrust hub Forward thrust hub Place a block of wood between gearcase and propeller and torque propeller nut to specifications. Description lb. in. lb. ft. Propeller nut 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. ob00422 Spark Plug Inspection And Replacement WARNING... -
Page 50: Lubrication Points
92-802865Q1 • Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets. ob01093 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑corrosion Grease or 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No. -
Page 51: Propeller Shaft
Propeller Shaft ‑ refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. ob00378 Lubricate the following with Quicksilver of Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No. - Page 52 MAINTENANCE ob00683 Swivel Bracket Tilt support lever • Tilt tube ‑ Lubricate through fitting. ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death.
-
Page 53: Checking Power Trim Fluid
Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid. -
Page 54: Submerged Outboard
Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 798 ml (27 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug. -
Page 55: Storage
Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). -
Page 56: Gearcase
STORAGE Tube Ref No. Description Where Used Part No. 92-802878Q5 Corrosion Guard External metal surfaces Gearcase • Drain and refill the gearcase lubricant (refer to Maintenance ‑ Gearcase Lubrication). Positioning Outboard For Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard. -
Page 57: Troubleshooting
TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •... -
Page 58: Performance Loss
TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged or improper size propeller. • Incorrect engine timing, adjustments, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •... -
Page 59: Local Repair Service
Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps. - Page 60 Telephone (954) 744‑3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3535 U.S.A. Japan Telephone 81‑053‑423‑2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81‑053‑423‑2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...
Need help?
Do you have a question about the 200 and is the answer not in the manual?
Questions and answers